Fiber matrix composite material made from recycled carpet

ABSTRACT

The invention relates to a composite structural material comprising a fiber dispersed in a fused matrix, wherein the fiber is derived from carpet, carpet recycle, carpet scrap, or mixtures thereof, and wherein the fused matrix comprises a thermoplastic comprising nylon, polyolefin, or mixtures thereof. The invention also relates to a method of manufacturing a rigid board composite structural material comprising the steps comminuting carpet to a predetermined particle size, adjusting the carpet feed stock to a form a balanced feed stock, introducing the feed stock into an extruder, and extruding the feed stock to form a structural composite comprising fiber dispersed in a fused matrix.

FIELD OF THE INVENTION

The invention relates to a substantially thermoplastic compositematerial. This material can be used in the fabrication of a structuralmember. The structural members formed from the composite material can beformed in a variety of products, for example, as a hollow profile, arigid board, a wallboard, a rail tie, tile backer board, roofingmaterials such as shingles and a substitute for sized lumber. Thecomposite of the invention is formed from virgin or recycledthermoplastic materials and can comprise carpeting material and optionaladded components and comprises carpet fiber dispersed in a fusedthermoplastic matrix. The invention also relates to a process forforming the composite material of the invention.

BACKGROUND OF THE INVENTION

Composite materials find a wide variety of uses in industrial andresidential applications. Composites are used in the form of rough-cutlumber, sheet components, panels, profiles including a hollow profile, arigid board, a wallboard, a rail tie, tile backer board, roofingmaterials such as shingles and a substitute for sized lumber and othergeneral construction components. Specifically such composites are usedfor resurfacing of trailers including snowmobile trailers andtruck/trailer beds, wagons, workbenches, and worktables. Additionally,composite materials are used to remodel and line walls, walkways, andlivestock pens. Composites are also used for decorative purposes, suchas in arts and crafts, or for other functional applications, such as toform signboards.

Such a composite requires the necessary chemical, and mechanicalproperties needed to fulfill its role in so many varied forms and enduses. In all applications the material must have the structuralproperties needed to withstand manufacture and transportation forces,various installation forces and loadings placed on the material afterinstallation. In outdoor applications, the composite must possessadequate moisture resistance to prevent degradation or leakage from rainand humidity. When used, as surfacing for workbenches or trailers, acomposite must be resistant to solvents, degreasing agents, and otherchemicals with which it may come into contact. Additionally, thecomposite must be resistant to damage caused by rodents, insects, andother pests. In addition to the foregoing properties, a compositematerial should be relatively easy for the installer to worth with.Composites must be sawed, screwed, nailed, drilled and machined usingcommon wood and metal tooling. Therefore, a substantial need exists foran economical composite material that possesses outstanding physical,chemical, and mechanical properties.

SUMMARY OF THE INVENTION

An economical composite material providing a combination of outstandingphysical, chemical, mechanical, and thermal properties can be formedusing material derived from nylon fiber in a thermoplastic matrixcomprising a nylon polymer resin and a polyolefin resin. In oneembodiment the composite can comprise carpeting recycle wherein thecomposite material comprises carpet fibers dispersed within a fusedthermoplastic matrix derived form carpet components comprising nylonpolymer resin and polyolefin resin. Carpet can be made from fiber thatis taken and converted into the form of an individual fiber and combinedinto the form of a yarn, tow or fiber bundle. Fiber, in the terms of theinvention, can refer to the separated or chopped individual fiberderived from recycled carpet and to the unwoven fiber used in carpetweaving. The term fiber can also relate to the to the comminuted fiber,chopped multi fiber yarn, processed tow or fiber bundle materials makingup the material inputs. The fiber, fiber tow or fiber bundle can have adiameter of about 0.2 mm to 7 cm, 0.2 mm to 1 cm or about 0.2 mm to 5mm.

The composite material is resistant to moisture, solvents, degreasingagents, insects and rodents. The material possesses a smooth consistencywith superior flexibility, surface durability, and high compressivestrength. The composite can be sawed, screwed, nailed, drilled andmachined using common tools. The material paint bonds easily with anaqueous or oil-based primer, and can be applied as a laminate, shaped orcontoured, or heat formed. The high water resistance of the compositerenders it ideal for outdoor applications, such as railroad ties,construction framing, agricultural buildings, wherein the material willbe exposed to extremes of moisture and humidity. The properties of thecomposite material can also render it an excellent substitute for lumberin some applications. The composite has been found to be longer lastingthan wood and wood products such as wood profiles, structural members,and sized lumber. Many wood products are slowly becoming scarce and moreexpensive as demand increases. The composite material can also be usedas a superior, economical substitute for structural members such as woodand concrete railroad ties, since the composite is substantially moreresistant to flexing and cracking problems commonly encountered withconcrete, wooden members and other materials.

Therefore, the present invention comprises a composite structuralmaterial comprising a fiber dispersed in a fused matrix. In oneembodiment, the composite comprises fiber derived from carpet, carpetrecycle, carpet scrap, or mixtures thereof. In one embodiment, the fusedmatrix comprises a thermoplastic comprising polyolefin, a polyamide suchas nylon, or mixtures thereof. The composite structural material has aflexural elastic modulus (ASTM D790) of at least about 2·10⁵.

The invention also comprises a method of manufacturing a rigid boardcomposite structural material. The method broadly comprises comminutingcarpet to a suitable particle size, optionally adjusting the carpet feedstock so that the content of the feed is about 25-35% nylon, introducingthe carpet feed stock into an extruder, and extruding the carpet feedstock to form a composite comprising fiber dispersed in a fused matrix.

DETAILED DESCRIPTION OF THE INVENTION

An economical composite material providing a combination of outstandingphysical, chemical, mechanical, and thermal properties can be formedusing material derived from nylon fiber in a thermoplastic matrixcomprising a nylon polymer resin and a polyolefin resin. In oneembodiment the composite can comprise carpeting recycle wherein thecomposite material comprises carpet fibers dispersed within a fusedthermoplastic matrix derived form carpet components comprising nylonpolymer resin and polyolefin resin.

An economical method of manufacturing a composite structural material isalso an aspect of the invention. Broadly speaking, the method comprisescomminuting carpet to a predetermined size range, adjusting the carpetfeed stock to form a balanced carpet feed stock, introducing the carpetfeed stock into an extruder, and extruding the feed stock to form astructural composite comprising fiber dispersed in a fused matrix.

The composition of the thermoplastic input can affect the compositeproperties. Nylon fiber is selected with a blend of polymer input toform the desired proportions of materials and mechanical properties. Ina preferred embodiment, carpeting selected for use in the methods of theinvention can affect the properties of the composite material. Standardcarpeting is composed of at least three major components: fibers formedinto a plurality of tufts, a backing material, and an adhesiveconstruction material. The fibers are typically polyamide (i.e. nylon)fibers. Carpeting fibers may also be formed using any other suitablepolymers. The backing material is commonly formed from a polyolefin suchas polypropylene. Less commonly, the backing may be formed from naturalfiber such as jute. The adhesive is commonly an aqueous dispersion of apolymer and other adhesive components, a hot melt thermoplasticadhesive, often an ABA block copolymer such as a styrene-butadienerubber. The adhesive is used to anchor the tufts to the backing and isapplied to the backing in the form of a hot melt that solidifies withcooling or a compounded aqueous emulsion that is later cured with heatdrying. The composite can comprise a blend of any of these carpetingmaterial and can also comprise virgin materials and fibers.

Any conventional carpeting type can be used in the methods of theinvention. In a preferred embodiment, the carpeting used is comprised ofnylon tufts, and can be formed from any suitable nylon polymer ormixtures of nylon polymers. In one embodiment, the tufts are formed fromnylon 6. In another embodiment, the tufts are formed from nylon 6,6. Inanother embodiment, the carpeting tufts comprise a blend of nylon 6 ornylon 6,6. In yet another embodiment, the carpeting tufts comprisecopolymers of nylon 6 and/or nylon 6,6. The nylon content of the carpetwill vary with the type of carpet itself. In one embodiment, thecarpeting used contains from about 10% to about 90% by weight of a nylonpolymer or mixture of nylon polymers. In another embodiment, theselected carpeting contains from about 40% to about 55% by weight of anylon polymer or a mixture of nylon polymers. The invention alsoencompasses the use of carpeting containing non-polyamide tufts. Forexample, carpeting with polyester tufts are also suitable for formingthe composite material. The backing material used in the carpeting ispreferably a polyolefin. In a preferred embodiment, the backing ispolypropylene.

The carpeting used in the methods of the invention is generally newcarpet ends, carpet recycle, carpet scrap, or mixtures thereof.Preferably, the carpeting typically new and unsoiled recycle from amanufacturing or retail waste stream that would otherwise be disposed ofthrough incineration, burial in a landfill, or by other means. Thecarpeting may be irregular or otherwise damaged. Carpeting that does notmeet manufacturer specifications for quality and therefore cannot besold to a retail customer can be used. The carpeting may also be endpieces resulting from the cutting of carpeting to a size desired by acustomer, and of such small size or shape as to have no economical valuefor sale. Alternatively, the carpeting may be post consumer (used)carpeting that would otherwise be disposed of. In this case, thecarpeting is preferably inspected for removal of metal, hard particulateor other hard extruder damaging materials. While, the carpet does notrequire thorough cleaning to remove any dirt or other contaminantsbefore being formed into the composite material, cleaning can in certaininstances improve the processing environment.

In one embodiment of a method of manufacturing a structural compositematerial, the first step comprises forming a mixture of fiber comprisingnylon and a thermoplastic input, when needed, typically comprising nylonpolymer resin and polyolefin resin. New or virgin materials can be usedto enhance physical or chemical properties. The blended input can beheated to a temperature to form a portion of the input into a meltmatrix containing fiber from the input. The fiber in melt matrix isextruded into the products of the invention. In a second embodiment,comminuting the carpet to form a carpet feed stock having apredetermined particle size is a first step in composite manufacture.The particle size is selected to allow for easy separation of thecomponents of the carpeting, and to create a size that is optimal foruse in the extruder used to form the composite material from thecarpeting. In a preferred embodiment, the carpet feed stock is formed bycomminuting the carpet to a particle size of less than about 5centimeters (cm) or less than 3 cm. In some embodiments, the carpet iscomminuted into a particle size of about 1 inch (2.5 cm) or less. Insome embodiments, the carpet is comminuted into a particle size of about0.5 inches (1.25 cm) or less. The comminuting of the carpet size canalso influence the size of the carpet fibers that will form the fibersdispersed in the fused matrix of the composite product.

The relative amounts of the primary components of the carpeting presentin the carpet feed stock can also influence the properties of theresulting composite structural material. In one embodiment of theinvention, therefore, the carpet feed stock is adjusted so that the oneor more components of the carpeting are present in a predeterminedamount relative to the other components. In one embodiment, thecarpeting feed stock is adjusted so that the feedstock contains fromabout 20-wt % to about 50 wt % nylon. In a preferred embodiment, thecarpeting feed stock is adjusted so that the feedstock contains fromabout 25-wt % to about 35 wt % nylon. In one embodiment, the carpet feedstock is adjusted by separating and classifying the components making upthe carpeting (e.g., nylon 6, nylon 6,6, polypropylene).

The carpet feed stock may also be adjusted through the addition of othercomponents, such as make-up virgin polymer or virgin fiber. Low meltingthermoplastics can be added to aid in melt matrix formation to moreefficiently distribute heat throughout the feedstock, causing the feedstock to flow more smoothly through the extruder. Therefore, in someembodiments, the method involves the addition of a thermoplastic notderived from carpeting so that the matrix of the composite is formedfrom a blend of a thermoplastic derived from the carpeting and at leastone other thermoplastic from a different source. In one embodiment, theadded component is a thermoplastic, and is added to the carpet feedstock in the form of a pellet or flake thermoplastic resin. Someexamples of such thermoplastics include polystyrene, polypropylene, andpolyethylene.

The carpet feed stock may also be adjusted through the addition of stillother components. In some embodiments, reinforcing fibers are added tothe feedstock to enhance the tensile strength, stiffness, or otherdesirable properties in the formed composite material. Such fibers arewell known in the art and, by way of non-limiting example, include thosemade from metal fiber or expanded metal, engineering plastics such asKevlar®, nylons other than those otherwise present in the feedstock,engineered plastics, or glass.

The balanced carpet feed stock of the invention is introduced into anextruder, and extruded to form a composite structural material. Theinventors have discovered that the resulting structural compositematerial, comprising a fiber dispersed within a fused matrix, possessesexcellent physical, chemical, and mechanical properties.

The nature of the composite material will be influenced by the meltingpoint of the input components and the temperatures within the extruder.In the composite, the fiber is derived from the carpet, carpet recycle,carpet scrap, or mixtures thereof, while the fused matrix comprisesthermoplastic derived from carpet, carpet recycle, carpet scrap, ormixtures thereof, or from another source. One of skill in the art willreadily recognize that which component of the carpeting forms the fiberand which component forms the fused matrix will be influenced by thetemperatures inside the extruder along with the relative melting pointsof the carpeting components. The temperatures within the extruder areselected so that as the carpet feed stock is fed through the extruder,the carpet component or components having the lowest melting point orpoints melt to form the fused matrix of the composite material. Thetemperature within the extruder is further selected to be low enoughsuch that the higher melting component of the carpeting is not melted,but retains its characteristic fiber structure within the formed fusedmatrix.

In one embodiment, the temperatures within the extruder are selected tobe low enough that the tufts of the carpeting maintain their fibrousstructure, while high enough such that the backing of the carpetingmelts to form the fused matrix. In a preferred embodiment, the carpetfeed stock comprises a blend of nylon 6 and nylon 6,6 tufts, the backingcomprises polypropylene, and the temperatures within the extruder areselected so that the polypropylene melts to form the fused matrix, whilethe nylon 6/nylon 6,6 nylon fibers retain their fibrous structure andbecome dispersed within the polypropylene fused matrix. The meltingpoint of nylon 6 is commonly 220-230° C., while the melting point ofnylon 6,6 is commonly 245-255° C. The melting point of polypropylene, onthe other hand, is commonly 150-160° C.

One of skill in the art will appreciate that the temperatures within theextruder can be selected to take advantage of these differential meltingpoints to create a composite material wherein the polypropylene melts toform the fused matrix, while the nylon fibers retain their fibrousstructures within the composite. In one embodiment of the invention, theextruder comprises at least one-barrel zone temperature of greater thanabout 250° C. In another embodiment, the extruder comprises at leastone-barrel zone temperature of greater than about 300° C.

The pressure at which the carpet feed stock is extruded also influencesthe nature of the structural composite material. In one embodiment, thecarpet feed stock is extruded at pressures above about 1.5·10³ psi. Inanother embodiment, the carpet feed stock is extruded at pressures aboveabout 2·10³ psi.

Without wishing to be limited by theory, the melt processing of thecarpet feed stock within the extruder causes the fused matrix-formingcomponent of the carpet, usually a lower melting point component of thecarpet, to melt and perhaps partially decompose. A second component,typically a higher melting point component of the carpeting, may bechemically modified but retains a characteristic fibrous structurewithin the melt matrix of the composite material. During the meltingprocess, either or both of the components that form the fiber and fusedmatrix may be chemically modified. For example, the components may reactwith each other, or with other components. Or, the components mayundergo oxidation caused by exposure to the atmosphere within theextruder. In the final composite material, however, the componentforming the fused matrix will melt sufficiently to form a fused matrix,while the component forming the fibers will substantially form or retaina characteristic fibrous structure that is dispersed within the fusedmatrix. After exiting the extruder the fiber is held in the matrix andcools to a rigid structural material. Thus, the methods of the inventioncan result in the formation of a structural composite material derivedfrom carpeting, but wherein the components of the carpeting are notmelt-blended together. Rather, the composite material comprises fibersdispersed within, and intimately contacted by, a fused matrix material.

In a preferred embodiment, the fused matrix of the composite material isformed by polypropylene, while nylon and nylon 6,6 forms fibersdispersed within the fused matrix. In accordance with the foregoingtheory, therefore, the nylon 6 and nylon 6,6 fibers may be chemicallymodified, but retain their characteristic fibrous structure within thefused matrix of the formed composite material, while the polypropylenebacking melts and perhaps partially decomposes, but forms a melt inwhich the nylon fibers are embedded and adhered in the final composite.In these structures, due to the variation in the nature of polymermaterials, the changes in the materials resulting from melt processingand the solubility of polymer in polymer, the fiber may acquire someproportion of matrix polymer and the matrix may acquire some proportionof fiber polymer.

The properties of the composite formed by the methods of the inventionare also influenced by the rate at which the carpet feed stock isintroduced into, and moved through, the extruder. The rate must beselected to allow sufficient time for the lower melting componentintended to form the fused matrix to undergo the necessary extent ofmelting. The rate must be fast enough, however, so that the highermelting material intended to form the fiber dispersed within the fusedmatrix does not melt. The fibrous structure of the material is thusmaintained in the resulting composite material product. The proper rateof introduction into the extruder, therefore, will necessarily vary withthe melting points of the components used to form the fibers and thefused matrix. Selection of the proper extrusion rate based upon themelting points and other characteristics of the components making up thecarpet feed stock can be easily established. Similarly, the rate atwhich the composite is extruded will vary according to several factors,including the moisture content of the composite and the thickness of theextruded material. In one embodiment, the rate of extrusion is fromabout 15 inches (160 cm)/minute to about 125 inches (300 cm)/minute.

Those of skill in the art will readily recognize that the compositematerial can be extruded into a wide variety of shapes and sizes toaccommodate the desired application. The composite may, for example, beformed into a rigid board. Alternatively, the board may take on anydesired geometric shape including, but not limited to, a rectangular,square, circular, or asymmetric form.

The composite material may also be formed to have any desiredcross-sectional profile. The material may be formed as a hollow memberor a solid, filled member. The composite may be extruded to take on athree-dimensional profile appropriate to form, for example, a doorframe, a window frame, or a pipe.

In one embodiment, the composite has an arbitrary cross-section and across-sectional area of from about 10² cm² to 2·10⁶ cm². In oneembodiment, the composite is formed into a shape having a thickness offrom about 0.1 to about 2 centimeters and an indeterminate length. Inone embodiment, the composite is formed to have a width of about 2 to200 centimeters and an indeterminate length. In one embodiment, thelength of the composite is less than about 10 meters. In one embodiment,the composite has a thickness of from about 0.1 to about 2 centimeters,a width of about 2 to 200 centimeters, and an indeterminate length.

Another aspect of the invention includes a composite structural materialcomprising a fiber dispersed in a fused matrix. In one embodiment, thefiber is derived from carpet, carpet recycle, carpet scrap, or mixturesthereof, and dispersed within a fused matrix. The fused matrix comprisesa thermoplastic, and in one embodiment, the thermoplastic comprises apolyolefin, a polyamide such as nylon, or mixtures thereof. Thethermoplastic may comprise a thermoplastic derived from carpeting.Alternatively, the matrix may comprise a blend of thermoplastic and athermoplastic derived from a carpet. In yet another embodiment, thematrix may comprise a blend of a thermoplastic and a blend of two ormore carpet sources.

In one embodiment, the matrix comprises about 20 to about 30 wt % nylon.In another embodiment, the matrix comprises about 0.1 to about 30 wt. %nylon 6. In yet another embodiment, the matrix comprises about 0.1 toabout 30 wt % nylon 6,6.

In one embodiment, the composite material comprises about 25 to 35 wt %nylon. In another embodiment, the composite comprises about 0.1 to about35 wt % nylon 6. In another embodiment, the composite comprises about0.1 to 35 wt % nylon 6,6. In yet another embodiment, the compositecomprises about 25 to 35 wt % of a polymer selected from nylon 6, nylon6,6, or mixtures thereof, and about 35 wt % polyolefin by weight.

The fiber and/or fused matrix of the structural composite material canbe derived from any conventional carpet. In one embodiment, the carpetcomprises about 0 to 35 wt % nylon 6, about 0.1 to 35 wt % nylon 6,6 andabout 25 to 35 wt % polyolefin by weight. In another embodiment, thecarpet comprises about 20 to 40 wt % nylon 6, about 20 to 40 wt % nylon6,6, and about 20 to 40 wt % polyolefin by weight.

The individual fibers that are dispersed within the fused matrix of thecomposite may vary in size, diameter, and structure. Due to the manyvariables of the melting and extrusion process, the composite may beformed to have these variations within a single, extruded material.Alternatively, the variables may be controlled to produce a compositewherein the fibers possess a defined range of size, diameter, orstructure. In some embodiments the composite material includes somefibers that are partially melted, and other fibers that remain unmeltedand are held together by other melted components, such as nylon orpolypropylene

The structural composite material possesses excellent flexibilityparameters allowing it to be useful in applications requiring a rigidcomposite material. In one embodiment, the composite material has aflexural elastic modulus (ASTM D790) of at least about 2·10⁵ psi. Inanother embodiment, the composite material has a flexural elasticmodulus (ASTM D790) of at least about 2·10³ psi. In another embodiment,the composite material has a flexural elastic modulus (ASTM D790) of atleast about 2.5·10³ psi. In another embodiment, the composite materialhas a flexural elastic modulus (ASTM D790) of at least about 6·10³ psi.In yet another embodiment, the composite material has a flexural elasticmodulus (ASTM D790) of at least about 6.5·10³ psi.

The composite structural material also exhibits excellent resistance tomoisture. In one embodiment, the composite material has a waterabsorption of less than about 3% by weight gain of water over a 24 hourperiod. This water resistance makes the composite an excellent candidatefor use in moisture-rich environments, particularly in outdoorapplications where the material will be exposed to the elements.

The composite structural material exhibits high compressive strength aswell. In one embodiment, the composite material has a compressivestrength (ASTM D695) of at least about 6.5·10³ psi.

The composite material additionally exhibits excellent tensile strength.In one embodiment, the composite material has a tensile strength (ASTMD638) of at least about 2·10³. In another embodiment, the compositematerial has a tensile strength (ASTM D638) of at least about 2.5·10³.

The structural composite material may be cosmetically altered orotherwise structurally altered to adapt it for optimal use and/orappearance in a given application. For example, the material maycomprise a dye or co-extruded cover layer to produce a desired color forthe composite. Due to the presence of fibers dispersed within the matrixof the composite, the fibers can be brushed and raised from thecomposite as individual carpet fibers during processing of the material.The composite may also be imprinted with a design, or with grooves orpatterns. For example, the composite material may be imprinted with apattern of grooves that serves to increase traction, adhesion of tile orother material, on the surface for applications involving use of thecomposite material to resurface areas that may be walked upon. Othertextures such as that resembling rough lumber, concrete surface, acomposite or shake shingle, etc. can be added to the surface.

The composite material of the invention may be formed into anyappropriate size and/or shape. In a preferred embodiment, the compositematerial is formed into a sheet. In one embodiment, the sheet has athickness of about 0.1 centimeter to about 2 centimeters. In anotherembodiment, the sheet has a width of about 2 centimeters to about 200centimeters.

The following examples were performed to further illustrate theinvention that is explained in detail above. The following informationillustrates the typical production conditions and compositions. Thefollowing examples and data contain a best mode.

EXAMPLE 1

A composite material was extruded according to a method of theinvention. The material was then tested according to standard proceduresto quantify various physical properties relevant to its use incommercial applications.

A sample of carpeting comprised of polypropylene backing and nylon tuftswas shredded into 1 inch (2.5 cm±10%) chunks, such that the length ofthe individual carpet fibers were between {fraction (3/8)} inch (0.95cm) and 3 inches (7.6 cm) long. The carpet chunks were then introducedinto an NRM extruder having a screw ratio of 30 to 1. The extruder wasset at temperatures of 550 to 660° F. (290 to 350° C.). The barrelpressure of the NRM ranged from 600 psi (4 MPa) to 2100 psi (14.5 MPa).The composite material was extruded through a 54″ (7 cm) EDI die at arate of 47 inches (120 cm)/minute, and at a temperature of between 510to 560° F. (266 to 294° C.). The product was then sent through a threeroll stacked chill roll system and formed into a 0.25 in×4 ft×8 ft (0.64cm×1.2 m×2.4 m) sheet. The sheet was then cut into samples that measured0.25 in×1 in×4 in (0.64 cm×2.5 cm×10 cm) in a standard dog bone shape.The sample was then cut down in the middle to 0.375 in (0.95 cm) wide toresemble a dog bone design.

Samples of the composite structural material were tested for flexibilityusing the standard ASTM D790, and compared to the flexibility of plywoodsamples. The data in Table I provide the flexural elastic modulusratings for the composite produced according to Example 1. For purposesof comparison, Tables II and III provide the flexural elastic modulusdata for plywood samples (with grain) and plywood samples (with crossgrain), respectively.

As can be seen from the data, representative samples of the compositestructural material exhibits uniform superior flexibility propertiesrelative to the plywood samples. TABLE 1 NYLON BOARD, ♯3/8♭ INCH FLEXTEST Displacement Load Stress Strain at Yield at Yield at Yield at YieldModulus Width Depth (Max Load) (Max Load) (Max Load) (Max Load)(AutYoung) (in) (in) (in) (lbf) (psi) (in/in) (psi) 1 0.510 0.387 0.62834.6 4082 0.0405 254088 2 0.510 0.382 0.842 33.0 3993 0.0536 239850 30.508 0.382 0.602 31.4 3813 0.0383 209771 4 0.510 0.382 0.689 31.4 37990.0439 269231 5 0.510 0.384 0.639 34.6 4146 0.0409 215202 Mean 0.5100.383 0.680 33.0 3966 0.0434 237628 S.D. 0.001 0.002 0.096 1.6 1560.0060 25266 C.V. 0.176 0.571 14.104 4.9 4 13.8491 11

TABLE II PLYWOOD FLEX TEST (WITH GRAIN) Displacement Load Stress Strainat Yield at Yield at Yield at Yield Modulus Width Depth (Max Load) (MaxLoad) (Max Load) (Max Load) (AutYoung) (in) (in) (in) (lbf) (psi)(in/in) (psi) 1 1.479 0.468 0.256 244.8 9068 0.0112 1076902 2 1.4820.470 0.161 206.2 7558 0.0071 1251806 3 1.483 0.471 0.327 285.1 103990.0114 1209800 4 1.484 0.469 0.143 181.2 6661 0.0063 1131028 5 1.4860.472 0.212 215.0 7793 0.0094 1120369 Mean 1.483 0.470 0.220 226.5 82960.0097 1157981 S.D. 0.003 0.002 0.075 39.9 1457 0.0033 71069 C.V. 0.1750.336 33.908 17.6 18 33.9821 6

TABLE III PLYWOOD FLEX TEST, CROSS GRAIN Displacement Load Stress Strainat Yield at Yield at Yield at Yield Modulus Width Depth (Max Load) (MaxLoad) (Max Load) (Max Load) (AutYoung) (in) (in) (in) (lbf) (psi)(in/in) (psi) 1 1.480 0.469 0.326 142.6 5256 0.0143 459834 2 1.487 0.4690.633 103.9 3812 0.0278 257273 3 1.486 0.471 0.427 135.3 4925 0.0189384053 4 1.486 0.471 0.430 115.2 4193 0.0190 261337 5 1.464 0.471 0.305120.8 4463 0.0135 389428 Mean 1.481 0.470 0.424 123.6 4530 0.0187 350385S.D. 0.010 0.001 0.130 15.5 574 0.0057 88369 C.V. 0.654 0.233 30.62112.6 13 30.4875 25

Table IV displays the results of testing the composite material for itsability to resist water absorption. The test was conducted on a 0.25inch (0.64 cm) thick nylon board produced according to Example 1. TheASTM standard for water absorption of plastics (D570) was followedthroughout the test. Three specimens were dried in an oven for 24 hoursat 50° C. They were then cooled in a desiccator, and immediatelyweighed. The conditioned specimens were placed in a container ofdistilled water maintained at 23° C. for 24 hours. The specimens werethen removed from the water one at a time; all surface water was wipedoff with a dry cloth, and they were then weighed. The balance used inthe test was a Satorius MCI model AC210 S. This balance has a claimedreproducibility (standard deviation) to within 0.0001 g. The results ofthe test demonstrate that the composite material of the inventionexhibits excellent resistance to moisture, and displays less than a 3%gain in weight in the absorption test. TABLE IV RESULTS FOR WATERABSORPTION Weight (g) Weight Weight Thickness Weight after (g) gain %gain after exposure (g) before exposure after 24 hr after 24 hr Specimen# Diameter (in) Thickness (in) (in) exposure (24) hr period period 1 20.256 0.261 16.8210 17.3016 0.4806 2.86% 2 2 0.254 0.261 17.2750 17.77520.5002 2.90% 3 2 0.257 0.262 16.8970 17.3985 0.5015 2.97% Average 2.91%St Dev 0.001 COV 1.94%

Table V displays the results obtained from testing the compositematerial for compressive strength. The test was performed according toASTM D 695 at 68° F. at ambient humidity of 30%. TABLE V COMPRESSIONTEST, ROOM TEMP Displacement Load Stress Strain at at at at ModulusWidth Thickness (Max Load) (Max Load) (Max Load) (Max Load) (ManYoung)(in) (in) (in) (lbf) (psi) (in/in) (psi) 1 0.508 0.255 0.217 961.607423.19 0.1447 121410.0 2 0.506 0.257 0.231 857.40 6593.25 0.1540114566.3 3 0.507 0.256 0.234 889.40 6852.50 0.1560 116572.4 4 0.5050.256 0.242 907.60 7020.42 0.1613 120003.5 5 0.505 0.254 0.234 874.606818.43 0.1560 120132.2 Mean 0.506 0.256 0.232 898.12 6941.56 0.1544118536.9 S.D. 0.001 0.001 0.009 40.02 309.27 0.0061 2853.8 C.V. 0.2580.446 3.941 4.46 4.46 3.9408 2.4

Table VI displays the results obtained from testing the compositematerial using the ASTM D-638 tensile test. The test was performed at atemperature of 130° F., and at a humidity level of 34%. TABLE VI FIBERREINFORCED PLASTIC TENSILE TEST ASTM D-638, 130° F. Displacement LoadStress Strain at at at at Modulus Width Depth (Max Load) (Max Load) (MaxLoad) (Max Load) (AutYoung) (in) (in) (in) (lbf) (psi) (in/in) (psi) 10.512 0.257 0.084 217.400 1652.18 0.0842 157055.5 2 0.509 0.255 0.057223.900 1725.03 0.0572 187135.2 3 0.510 0.255 0.101 230.300 1770.860.1008 191744.4 4 0.510 0.256 0.118 218.300 1672.03 0.1178 171881.1 50.512 0.257 0.123 207.000 1573.14 0.1228 106031.7 Mean 0.511 0.256 0.097219.380 1678.65 0.0966 162769.6 S.D. 0.001 0.001 0.027 8.632 75.050.0267 34525.6 C.V. 0.263 0.391 27.688 3.935 4.47 27.6877 21.2

The data in the foregoing tables clearly demonstrates the excellentphysical, chemical, and mechanical properties of the composite materialof the invention. The material exhibits properties of durability,moisture resistance, compressive strength, and tensile strength thatrender it an excellent material for use in a wide variety ofapplications, indoor and outdoor, and as substitutes for other, moretraditional materials such as lumber and concrete.

EXAMPLE 2

A composite material is extruded according to a method of the invention.A sample of carpeting comprised of polypropylene backing and nylon tuftsis shredded into 1 inch (2.54 cm) chunks, such that the length of theindividual carpet fibers were between {fraction (3/8)} inch (0.95 cm)and 3 inches (7.6 cm) long. Virgin metallocene polypropylene polymer (MI1.5 gm-10 min⁻¹) is introduced into the extruder. The carpet chunks arethen introduced into an NRM extruder having a screw ratio of 30 to 1.The extruder is set at temperatures of 550 to 660° F. (290 to 350° C.).The barrel pressure of the NRM ranges from 600 psi (4 MPa) to 2100 psi(14.5 MPa). The composite material is extruded through a 54″ (7 cm) EDIdie at a rate of 47 inches (120 cm)/minute, and at a temperature ofbetween 510 to 560° F. (266 to 294° C.). The product is then sentthrough a three roll stacked chill roll system and formed into a 0.25in×4 ft×8 ft (0.64 cm×1.2 m×2.4 m) sheet. The sheet is then cut intosamples that measured 0.25 in×1 in×4 in (0.64 cm×2.5 cm×10 cm) in astandard dog bone shape. The sample was then cut down in the middle to0.375 in (0.95 cm) wide to resemble a dog bone design.

EXAMPLE 3

A composite material is extruded according to a method of the invention.A sample of carpeting comprised of polypropylene backing and nylon tuftsis shredded into 1 inch (2.54 cm) chunks, such that the length of theindividual carpet fibers were between {fraction (3/8)} inch (0.95 cm)and 3 inches (7.6 cm) long. Virgin Kevlar reinforcing fiber (10 cmlength and about 10 micron diameter) is introduced into the extruder anda weight ratio of about 1 part Kevlar fiber per 10 parts of carpetrecycles to form a carpet chunk blend. The carpet chunk blend is thenintroduced into an NRM extruder having a screw ratio of 30 to 1. Theextruder is set at temperatures of 550 to 660° F. (290 to 350° C.). Thebarrel pressure of the NRM ranges from 600 psi (4 MPa) to 2100 psi (14.5MPa). The composite material is extruded through a 54″ (7 cm) EDI die ata rate of 47 inches (120 cm)/minute, and at a temperature of between 510to 560° F. (266 to 294° C.). The product is then sent through a threeroll stacked chill roll system and formed into a 0.25 in×4 ft×8 ft (0.64cm×1.2 m×2.4 m) sheet. The sheet is then cut into samples that measured0.25 in×1 in×4 in (0.64 cm×2.5 cm×10 cm) in a standard dog bone shape.The sample was then cut down in the middle to 0.375 in (0.95 cm) wide toresemble a dog bone design.

While the invention has been set forth above in detail, one of skill inthe art will readily recognize that various modifications to theinvention can be made, without departing from the spirit of theinvention.

1. A composite structural material comprising a fiber dispersed in afused matrix, the composite comprising: nylon fiber having a length ofabout 0.9 cm to 8 cm and a diameter of about 0.2 mm to 7 cm, dispersedin a fused matrix, the fused matrix comprising a thermoplasticcomprising a nylon and a polyolefin; wherein said composite structuralmaterial has a flexural elastic modulus (ASTM D790) of at least about2·10⁵ psi.
 2. The composite material of claim 1, wherein said matrixcomprises about 20 to 30 wt.-% Nylon and about 1 to 40 wt.-% of apolypropylene.
 3. The composite material of claim 1, wherein said matrixcomprises about 0.1 to 30 wt.-% Nylon 6 and about 1 to 40 wt.-% of apolypropylene.
 4. The composite material of claim 1, wherein said matrixcomprises about 0.1 to 30% Nylon 6,6 and about 1 to 40 wt.-% of apolypropylene.
 5. The composite material of claim 1, wherein said matrixcomprises a blend of a virgin thermoplastic and thermoplastic derivedfrom a carpet and the fiber has a diameter of about 0.2 mm to 1 cm. 6.The composite material of claim 1, wherein said matrix comprises a blendof a virgin thermoplastic and a blend of two or more carpet sources. 7.The composite material of claim 1, wherein said composite comprisesabout 25 to 35 wt.-% Nylon and about 1 to 40 wt.-% of a polypropylene.8. The composite material of claim 1, wherein said composite comprisesabout 0.1 to 35 wt.-% Nylon 6 and about 1 to 40 wt.-% of apolypropylene.
 9. The composite material of claim 1, wherein saidcomposite comprises about 0.1 to 35% Nylon 6,6 and about 1 to 40 wt.-%of a polypropylene.
 10. The composite material of claim 1, wherein saidcarpet comprises about 1 to 35 wt.-% Nylon 6, about 0.1 to 35 wt.-%Nylon 6,6 and about 25 to 35 wt.-% polyolefin.
 11. The compositematerial of claim 1, wherein said carpet comprises about 20 to 40 wt.-%Nylon 6, about 20 to 40 wt.-% Nylon 6,6 and about 20 to 40 wt.-%polyolefin.
 12. The composite material of claim 1, wherein saidcomposite material has a flexural elastic modulus (ASTM D790) of atleast about 2·10⁵ psi.
 13. The composite material of claim 1, whereinsaid composite material has a tensile strength (ASTM D638) of at leastabout 2·10³ psi.
 14. The composite material of claim 1, wherein saidcomposite material has a tensile strength (ASTM D638) of at least about2.5·10³ psi.
 15. The composite material of claim 1, wherein saidcomposite material has a compressive strength (ASTM D695) of at leastabout 6·10³ psi.
 16. The composite material of claim 1, wherein saidcomposite material has a compressive strength (ASTM D695) of at leastabout 6.5·10³ psi.
 17. The composite material of claim 1, wherein saidcomposite material has a water absorption of less than about 3% byweight gain of water over a 24 hour period.
 18. The composite materialof claim 1, further comprising at least one dye.
 19. A sheet formed fromthe composite material of claim 1 having a thickness of about 0.1centimeter to about 2 centimeters.
 20. A sheet formed from the compositematerial of claim 1 having a width of about 2 centimeters to about 200centimeters.
 21. A composite structural material comprising a fiberdispersed in a fused matrix, the composite comprising: fiber having adiameter of about 0.2 mm to 7 cm, derived from carpet, carpet recycle,carpet scrap or mixtures thereof, dispersed in a fused matrix, the fusedmatrix comprising a thermoplastic comprising nylon, polyolefin ormixtures thereof; wherein said composite structural material has aflexural elastic modulus (ASTM D790) of at least about 2·10⁵ psi. 22.The composite material of claim 21, wherein said matrix comprises about20 to 30 wt.-% Nylon.
 23. The composite material of claim 21, whereinsaid matrix comprises about 0.1 to 30 wt.-% Nylon
 6. 24. The compositematerial of claim 21, wherein said matrix comprises about 0.1 to 30%Nylon 6,6.
 25. The composite material of claim 21, wherein said matrixcomprises thermoplastic derived from carpet and the fiber has a diameterof about about 0.2 mm to 1 cm.
 26. The composite material of claim 21,wherein said matrix comprises a blend of a thermoplastic andthermoplastic derived from a carpet.
 27. The composite material of claim21, wherein said matrix comprises a blend of a thermoplastic and a blendof two or more carpet sources.
 28. The composite material of claim 21,wherein said composite comprises about 25 to 35 wt.-% Nylon.
 29. Thecomposite material of claim 21, wherein said composite comprises about0.1 to 35 wt.-% Nylon
 6. 30. The composite material of claim 21, whereinsaid composite comprises about 0.1 to 35% Nylon 6,6.
 31. The compositematerial of claim 21, wherein said composite comprises about 25 to 35wt.-% of a polymer selected from Nylon 6, Nylon 6,6 or mixtures thereofand about 35 wt.-% polyolefin by weight.
 32. The composite material ofclaim 21, wherein said carpet comprises about 0 to 35 wt.-% Nylon 6,about 0.1 to 35 wt.-% Nylon 6,6 and about 25 to 35 wt.-% polyolefin byweight.
 33. The composite material of claim 21, wherein said carpetcomprises about 20 to 40 wt.-% Nylon 6, about 20 to 40 wt.-% Nylon 6,6and about 20 to 40 wt.-% polypropylene by weight.
 34. The compositematerial of claim 21, wherein said composite material has a flexuralelastic modulus (ASTM D790) of at least about 2·10⁵ psi.
 35. Thecomposite material of claim 21, wherein said composite material has atensile strength (ASTM D638) of at least about 2·10³ psi.
 36. Thecomposite material of claim 21, wherein said composite material has atensile strength (ASTM D638) of at least about 2.5·10³ psi.
 37. Thecomposite material of claim 21, wherein said composite material has acompressive strength (ASTM D695) of at least about 6·10³ psi.
 38. Thecomposite material of claim 21, wherein said composite material has acompressive strength (ASTM D695) of at least about 6.5·10³ psi.
 39. Thecomposite material of claim 21, wherein said composite material has awater absorption of less than about 3% by weight gain of water over a 24hour period.
 40. The composite material of claim 21, further comprisingat least one dye.
 41. A sheet formed from the composite material ofclaim 21 having a thickness of about 0.1 centimeter to about 2centimeters.
 42. A sheet formed from the composite material of claim 21having a width of about 2 centimeters to about 200 centimeters.
 43. Acomposite structural material of claim 21 comprising a fiber dispersedin a fused matrix, wherein the material is formed by introducing acarpet feed stock into an extruder, and extruding the carpet feed stockto form a structural composite member.
 44. The composite material ofclaim 43, wherein the fiber is formed from a higher melting pointcomponent of the carpet feed stock, and the fused matrix is formed froma lower melting point component of the feed stock.
 45. A method ofmanufacturing a rigid board composite structural material comprising thesteps of: (a) comminuting carpet to a particle size less than about 3centimeters to form a carpet feed stock comprising fiber of claim 21,said fiber having a diameter of about 0.2 mm to 1 cm; (b) adjusting thecarpet feed stock to such that the content of the feed stock is about 25to 35 wt % nylon forming a balanced carpet feed stock; (c) introducingthe balanced carpet feed stock into an extruder having at least onebarrel zone temperature greater than about 250° C.; and (d) extrudingthe carpet feed stock to form a structural composite comprising fiberdispersed in a fused matrix, the composite having a thickness of about0.1 to 2 centimeters, a width of about 2 to 200 centimeters and anindeterminate length.
 46. The method of claim 45, wherein said carpetcomprises carpet ends, carpet recycle, carpet scrap or mixtures thereof.47. The method of claim 45, wherein said extruder has at least onebarrel zone temperature greater than about 250° C.
 48. The method ofclaim 45, wherein said extruder has at least one barrel zone temperaturegreater than about 300° C.
 49. The method of claim 45, wherein said feedstock is extruded at pressures above about 1.5·10³ psi.
 50. The methodof claim 45, wherein said carpet feed stock is extruded at pressuresabove about 2·10³ psi.
 51. The method of claim 45, wherein saidcomposite material is extruded to a thickness of from about 0.1 to 2centimeters.
 52. The method of claim 45, wherein the composite feedstock additionally comprises a pellet or flake thermoplastic resin. 53.The method of claim 45, wherein the length of the composite is less thanabout 10 meters.
 54. A composite structural material comprising a fiberdispersed in a fused matrix, wherein said composite structural materialhas a flexural elastic modulus (ASTM D790) of at least about 2·10⁵ psi.55. The composite of claim 54, wherein the composite comprises a blendof a polyolefin, a polyamide, and a hot-melted heat adhesive.
 56. Thecomposite material of claim 54, wherein said matrix comprises about 20to 30 wt.-% Nylon.
 57. The composite material of claim 54, wherein saidmatrix comprises about 0.1 to 30 wt.-% Nylon
 6. 58. The compositematerial of claim 54, wherein said matrix comprises about 0.1 to 30 wt %Nylon 6,6.